NHTSA ID Number: 10230486
Manufacturer Communication Number: TSB_ELE273
TSB/Document Date: 2023-02-02
Summary
TECHNICAL SERVICE BULLETIN: HIGH-VOLTAGE BATTERY
SAFETY PLUG FUSE INSPECTION AND REPLACEMENT - This bulletin provides information associated with the "Hybrid System Warranty Extension Program" (WTY029) to inspect and, if necessary, replace the High Voltage Battery (HVB) Safety Plug Fuse Assembly or Main Fuse on 2013-2016MY Optima Hybrid (TF HEV) vehicles produced from September 27, 2012 through July 22, 2015.
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TSB/Document ID: TSB_ELE273
Replacement Service Bulletin Number:
MFR Communication Date: 2023-01-13
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
GROUP
MODEL
ELE
2013-2016MY
Optima (TF HEV)
NUMBER
DATE
273
January 2023
TECHNICAL SERVICE BULLETIN
SUBJECT:
HIGH-VOLTAGE BATTERY SAFETY PLUG FUSE
INSPECTION AND REPLACEMENT
This bulletin provides information associated with the ‘Hybrid System Warranty Extension Program’
(WTY029) to inspect and, if necessary, replace the High Voltage Battery (HVB) Safety Plug Fuse Assembly
or Main Fuse on 2013-2016MY Optima Hybrid (TF HEV) vehicles produced from September 27, 2012
through July 22, 2015. The procedure outlined in this bulletin is to replace any non-genuine HVB Safety
Plug Fuse and to address ”Hybrid System Warning” message(s) with DTC(s) P1B77 and/or P1B25 stored in
the subject vehicles. The vehicle’s warranty for this issue will be extended from 10 years/100,000 miles to
15 years/150,000 miles, whichever comes first, starting from the date the vehicle was first put into service.
This extension to Kia’s Hybrid System Warranty does not alter the limitations and exclusions contained in
that Hybrid System Warranty including abuse, neglect, or external damage. Follow the procedure outlined
in this publication to inspect and, if necessary, replace the HVB Safety Plug Fuse Assembly or Main Fuse.
DTC Description:
P1B77: High Voltage Precharging Fault
P1B25: High Voltage Path Fault
NOTICE
Vehicles within 10/100 warranty coverage should utilize KGIS for diagnosis and LTS for the
applicable Labor Op Code. This TSB is specifically applicable to vehicles that exceed the 10/100
mileage parameter noted above.
A printed copy is for reference only; publication information can be updated at any time.
Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical
publications are listed in ‘Service Releases’ and has the latest service information that has been released.
Page 2 of 5
HIGH-VOLTAGE BATTERY SAFETY PLUG FUSE
INSPECTION & REPLACEMENT
SUBJECT:
Flowchart:
IMPORTANT
A vehicle may not come in with the “Hybrid System Warning” message displayed in cluster BUT, the
customer brought vehicle in knowing that an ‘aftermarket’ HV battery fuse is presently installed in
the vehicle, then confirm that the Extended Warranty of 15 Yr./150K Mile is applicable to replace
the Safety Plug Fuse Assembly using ‘Op Code’ 222136R4 (No DTC inspection required).
Vehicle In
Customer has knowledge
of an aftermarket Safety
Plug Fuse installed?
No
Hybrid System Warning
Message in Cluster
Is P1B77 and/or
P1B25 stored and/or
visible smoke/odor
present at the HV safety
plug?
No Extended
Warranty Coverage
No
Refer to Shop Manual
on KGIS for diagnosing.
Yes
Yes
Vehicle within Warranty
Extension Range?
(15 Yr./150K miles)
No
Yes
Labor Op Code
222136R4
Replace Safety Plug
Assembly
(Customer s Non-Genuine
Yes
Is non-genuine (aftermarket)
safety plug fuse installed?
Yes
Replace HVB
Safety Plug Assembly
(Non-Genuine Fuse present)
Fuse Awareness)
Labor Op Code
222136R0
No
Inspect safety plug
main fuse:
Is thermal deformation
present?
Replace Safety Plug
Assembly
Yes
(Genuine Fuse present
Labor Op Code
222136R1
w/Thermal Deformation)
No
Is safety plug
main fuse resistance
over 1 ?
No
Hybrid System Warning
Inspection
(Diagnosis Coverage Only)
Labor Op Code
222136R3
Yes
Replace HVB
Safety Plug Fuse Only
(High Voltage Main Fuse)
Labor Op Code
222136R2
NOTICE
Vehicles within standard 10 Yr./100K Mile warranty coverage should utilize KGIS for diagnosis
and LTS for the applicable Labor Op Code. This TSB is specifically applicable to vehicles that
exceed the 10 Yr./100K Mileage parameter noted above.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE273 Optima Hybrid (TF HEV) January 2023
Page 3 of 5
SUBJECT:
HIGH-VOLTAGE BATTERY SAFETY PLUG FUSE
INSPECTION & REPLACEMENT
Inspection and Replacement Procedure:
1.
Disconnect the auxiliary 12V battery negative
(-) cable located in the rear cargo area.
DANGER
Failure to follow the High Voltage
Shut-off Procedure may result in
serious electrical injuries.
2.
Open the High Voltage Battery (HVB) safety
plug service cover in the rear cargo area.
3.
Unlock the lever hook (A).
4.
Pull down on the lever (B).
5.
Remove the safety plug (C).
A
B
C
7.
Using a flathead screwdriver, remove the
safety plug cover (D) to expose the High
D
Voltage (HV) main fuse (E).
Note: OPEC 125A/150A is the Kia genuine fuse.
E
D
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE273 Optima Hybrid (TF HEV) January 2023
Page 4 of 5
HIGH-VOLTAGE BATTERY SAFETY PLUG FUSE
INSPECTION & REPLACEMENT
SUBJECT:
6.
Inspect the HV main fuse for any trace of
‘thermal deformation/burnout’ and if the HV
main
has
been
replaced
with
an
aftermarket (non-genuine Kia) fuse.
•
Thermal deformation or burnout is
present, replace Safety Plug Fuse
Assembly (150A) and skip to step 8.
•
A ‘non-genuine Kia’ HV main fuse is
present, replace Safety Plug Fuse
Thermal Deformation / Burnout
Assembly (150A) and skip to step 8.
•
No thermal deformation/burnout is
present and the main fuse is a genuine
Kia fuse, proceed to step 7.
Non-Genuine DC Fuse
7.
Using a multimeter, measure the HV main fuse
resistance.
•
Resistance is 1Ω or less (OK), refer to
the applicable Shop Manual on KGIS for
DTCs P1B77 and P1B25 to diagnose.
•
Resistance is over 1Ω (NG), replace the
HV Main Fuse only.
8.
Reassemble safety plug and main fuse in reverse order. Verify proper operation.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE273 Optima Hybrid (TF HEV) January 2023
Page 5 of 5
HIGH-VOLTAGE BATTERY SAFETY PLUG FUSE
INSPECTION & REPLACEMENT
SUBJECT:
AFFECTED VEHICLE RANGE:
Model
Production Date Range
Optima Hybrid (TF HEV)
September 27, 2012 to July 22, 2015
REQUIRED PART:
Part Name
Part Number
Safety Plug Fuse Assembly*
(Black Locking Hook)
Safety Plug Fuse Assembly*
(Green Locking Hook)
High Voltage Main Fuse
Figure
Qty.
37586 4R000ASFFF
1
37586 4R002FFF
1
375F2 4R150FFF
1
*Safety Plug Fuse Assembly includes a 150A fuse.
WARRANTY INFORMATION:
N Code: I3A C Code: ZZ3
Claim
Type
Causal P/N
Qty.
Repair
Labor Op
Op
Replacement
Description
Code
Time
P/N
Safety Plug Main Fuse
Inspection +
HVB Safety Plug Fuse
Assy Replacement
222136R0
0.3
M/H
(Non-Genuine Fuse present)
Safety Plug Main Fuse
Inspection +
HVB Safety Plug Fuse
Assy Replacement
37586 4R000
or
37586 4R002
(14-16MY Only)
M/H
(Genuine Fuse present
w/Thermal Deformation)
(13MY Only)
W
222136R1
0.3
0
Safety Plug Main Fuse
Inspection +
HV Main Fuse
Replacement Only
222136R2
0.3
M/H
Qty.
37586 4R000ASFFF
or
1
37586 4R002FFF
37586 4R000ASFFF
or
1
37586 4R002FFF
375F2 4R150FFF
1
N/A
0
(Resistance over 1Ω)
Hybrid System
Warning Inspection
222136R3
(Diagnosis Coverage Only)
HVB Safety Plug Fuse
Assy Replacement
w/Customer’s NonGenuine Fuse Awareness
(w/o DTC Inspection)
222136R4
0.3
M/H
0.2
M/H
37586 4R000ASFFF
or
1
37586 4R002FFF
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE273 Optima Hybrid (TF HEV) January 2023
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